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INSTALLATION
MANUAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . .4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . .5
APPROVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . .6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
START-UP (COOLING). . . . . . . . . . . . . . . . . . . . . .38
START-UP (GAS HEAT). . . . . . . . . . . . . . . . . . . . .38
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . .41
See following pages for a complete Table of Contents.
NOTES, CAUTIONS AND WARNINGS
The installer should pay particular attention to the words:
NOTE, CAUTION, and WARNING. Notes are intended to
clarify or make the installation easier. Cautions are given
to prevent equipment damage. Warnings are given to alert
installer that personal injury and/or equipment damage
may result if installation procedure is not handled properly.
CAUTION:
READ ALL SAFETY GUIDES BEFORE YOU
BEGIN TO INSTALL YOUR UNIT.
SAVE THIS MANUAL
SINGLE PACKAGE AIR CONDITIONERS AND
SINGLE PACKAGE GAS/ELECTRIC UNITS
12-1/2 TON
(11.35 EER)
Tested in accordance with:
DW-12
66389-BIM-C-1208
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Summary of Contents for Johnson Controls DW-12
- Page 1 INSTALLATION SINGLE PACKAGE AIR CONDITIONERS AND MANUAL SINGLE PACKAGE GAS/ELECTRIC UNITS DW-12 12-1/2 TON CONTENTS (11.35 EER) GENERAL ....... . .4 SAFETY CONSIDERATIONS .
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Page 2: Table Of Contents
EXHAUST -........33 Johnson Controls Unitary Products... - Page 3 19 FIELD WIRING DISCONNECT - COOLING UNIT DW-12 COMPONENT LOCATION ....8 WITH GAS HEAT ......18 UNIT 4 POINT LOAD .
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Page 4: General
Refer tions. to this manual. For assistance or additional informa- tion consult a qualified installer, service agency or the gas supplier. Johnson Controls Unitary Products... -
Page 5: Reference
Design certified by CSA as follows: forms: For use as a cooling only unit, cooling unit with supple- • Technical Guide - DW-12, 262776 mental electric heat or a forced air furnace. • General Installation - DW-12, 66389 For outdoor installation only. -
Page 6: Nomenclature
Y = Options 4 & 5 Z = Options 3, 4 & 5 Options 1 = Disconnect 2 = Non-Pwr'd Conv. Outlet 3 = Smoke Detector S.A. 4 = Smoke Detector R.A. 5 = Pwr'd Conv. Outlet Johnson Controls Unitary Products... -
Page 7: Installation
These units must be installed in accordance with the following: FIGURE 1 - UNIT SHIPPING BRACKET In U.S.A.: Turn each bracket toward the ground and the protective National Electrical Code, ANSI/NFPA No. 70 - Latest plywood covering will drop to the ground. Edition Johnson Controls Unitary Products... -
Page 8: Dw-12 Component Location
DU/DL/DW Series Compressor #1 access Side entry power Intelligent control (high-efficiency footprint are available and control wiring board for safe and compressor w/crankcase (field-installed accessory) knockouts efficient operation heater) FIGURE 3 - DW-12 COMPONENT LOCATION Johnson Controls Unitary Products... -
Page 9: Location
(e.g. perchloro- LEFT ethylene), printing inks, paint removers, varnishes, hydrochloric acid, cements and glues, antistatic fab- FIGURE 4 - UNIT 4 POINT LOAD ric softeners for clothes dryers, masonry acid wash- ing materials. Johnson Controls Unitary Products... -
Page 10: Clearances
• Cleaning solvents (such as perchloroethylene) • Printing inks, paint removers, varnishes, etc. FRONT LEFT • Hydrochloric acid • Cements and glues • Anti-static fabric softeners for clothes dryers FIGURE 6 - UNIT CENTER OF GRAVITY • Masonry acid washing materials Johnson Controls Unitary Products... -
Page 11: Unit Dimensions
NOTE: A one-inch clearance must be provided between • Four (4) feet from electric meters, gas meters, regula- any combustible material and the supply ductwork tors, and relief equipment. for a distance of 3 feet from the unit. Johnson Controls Unitary Products... -
Page 12: Bottom Duct Openings (From Above)
LEFT 27-1/2 21-3/16 19-3/16 17-3/16 12-5/16 7-1/8 FRONT 14-23/32 16-3/8 Bottom Bottom Bottom 18-1/16 Condensate Power, Control and Gas Supply Entry Drain Convenience Outlet 19-5/8 Wiring Entries 63-1/2 FIGURE 8 - BOTTOM DUCT OPENINGS (FROM ABOVE) Johnson Controls Unitary Products... -
Page 13: Ductwork
The return panel is Refer to Figure 8 for bottom air duct openings. Refer to Fig- secured with four screws. ure 9 for rear air duct openings. Johnson Controls Unitary Products... - Page 14 DO NOT insert screws through casing. Outdoor duct- work must be insulated and water-proofed. FIGURE 12 - SIDE PANELS WITH HOLE PLUGS Note orientation. Panel is “insulation” side up. Johnson Controls Unitary Products...
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Page 15: Condensate Drain
Voltage tolerances which must be maintained at the com- pressor terminals during starting and running conditions are indicated on the unit Rating Plate and Table 1. FIGURE 15 - CONDENSATE DRAIN Johnson Controls Unitary Products... -
Page 16: Power Wiring Detail
- b a c k p o s i t i o n . FIGURE 16 - TYPICAL ELECTRONIC THERMOSTAT FIELD WIRING Johnson Controls Unitary Products... -
Page 17: Field Wiring Disconnect - Cooling Unit With/Without Electric Heat
B O A R D FIGURE 17 - TYPICAL FIELD WIRING 24 VOLT THERMOSTAT TERMINAL BLOCK TB1 FACTORY OR FIELD SUPPLIED DISCONNECT GROUND THREE PHASE POWER SUPPLY FIGURE 18 - FIELD WIRING DISCONNECT - COOLING UNIT WITH/WITHOUT ELECTRIC HEAT Johnson Controls Unitary Products... -
Page 18: Field Wiring Disconnect - Cooling Unit
66389-BIM-C-1208 CONTACTOR 1M FACTORY OR FIELD SUPPLIED DISCONNECT GROUND THREE PHASE POWER SUPPLY FIGURE 19 - FIELD WIRING DISCONNECT - COOLING UNIT WITH GAS HEAT Johnson Controls Unitary Products... -
Page 19: Electrical Data Dw-12 (12-1/2 Ton) Without Powered Convenience Outlet
66389-BIM-C-1208 TABLE 8: ELECTRICAL DATA DW-12 (12-1/2 TON) WITHOUT POWERED CONVENIENCE OUTLET Max Fuse Size Supply Min. Circuit OD Fan w/Power Fuse w/Power Compressors Blower Conv Ampacity Motors Electric Heater Actual Heater Exhaust Size Exhaust Voltage Motor FLA Motor Outlet (Amps) Model No. -
Page 20: Optional Electric Heat
Fuses are supplied, where required, by the factory. Some kW 3750 sizes require fuses and other do not. Refer to Table 11 for minimum CFM limitations and to Tables 8 through 9 for elec- trical data. 3750 Johnson Controls Unitary Products... -
Page 21: Optional Gas Heat
NOTE: There may be a local gas utility requirement specify- ing a minimum diameter for gas piping. All units require a 3/4 inch pipe connection at the entrance fitting. Line should not be sized smaller than the entrance fitting size. Johnson Controls Unitary Products... -
Page 22: Gas Connection
The vaporization rate which depends on the temperature the mains. Check all joints for leaks with soap solution or of the liquid and the “wetted surface” area of the con- other material suitable for the purpose. NEVER USE A tainer(s). FLAME. Johnson Controls Unitary Products... -
Page 23: Vent And Combustion Air
All electric heaters are fused and intended for use with single point power supply. Follow the instructions included with the hood to com- plete the installation. Johnson Controls Unitary Products... -
Page 24: Economizer And Power Exhaust Set Point Adjustments And Information
"A", "B", "C" or "D" setting corresponding to the lettered curve of the Enthalpy Set Point Adjustment • Optional CO Sensor Kit Part # 2AQ04700424 Figure 22. Replace the top rear access panel on the unit. Johnson Controls Unitary Products... -
Page 25: Enthalpy Set Point Chart
Damper Min. Position Screw Indoor Air Quality Max. Adjustment Screw Indoor Air Quality Indoor Air Quality Min. Adjustment Screw Free Cool Free Cooling LED Economizer Enthalpy Set Point Adjustment Screw FIGURE 23 - HONEYWELL ECONOMIZER CONTROL W7212 Johnson Controls Unitary Products... -
Page 26: Phasing
Check the belt ten- sion at least two times during the first 24 hours of operation. Any retensioning should fall between the min. and max. deflection force values. 5. After adjusting retighten nuts (A). Johnson Controls Unitary Products... -
Page 27: Dw-12, 12-1/2 Ton Standard Motor Down Shot Blower Performance
66389-BIM-C-1208 TABLE 15: DW-12, 12-1/2 TON STANDARD MOTOR DOWN SHOT BLOWER PERFORMANCE TURNS OPEN 5078 3630 3.89 4809 3103 3.33 4594 3053 3.27 4360 2478 2.66 4090 2093 2.24 3812 1798 1.93 4865 3456 3.71 4584 2961 3.17 4349 2912 3.12... -
Page 28: Dw-12, 12-1/2 Ton Standard Motor Side Shot Blower Performance
66389-BIM-C-1208 TABLE 17: DW-12, 12-1/2 TON STANDARD MOTOR SIDE SHOT BLOWER PERFORMANCE TURNS OPEN 5201 3162 3.39 4966 2796 3.00 4681 2405 2.58 4355 2054 2.20 5220 3395 3.64 4942 2980 3.20 4657 2608 2.80 4358 2230 2.39 4007 1890 2.03... -
Page 29: Air Balance
CFM. Adjustments of the blower speed and belt tension are REQUIRED. Tighten blower pulley and motor sheave set screws after these adjustments. Re-checking set screws after 10-12 hrs. run time is recommended. Johnson Controls Unitary Products... -
Page 30: Checking Air Quantity
NOTE: With the addition of field installed accessories repeat this procedure. Failure to properly adjust the total system air quan- tity can result in extensive blower damage. Failure to properly adjust the total system air quan- tity can result in extensive blower damage. Johnson Controls Unitary Products... -
Page 31: Supply Air Drive Adjustment
Tighten blower pulley and motor sheave set screws HP motor, but the unit is delivering 3,800 CFM. The variable after these adjustments. Re-checking set screws pitch motor sheave is set at 2 turns open. after 10-12 hrs. run time is recommended. Johnson Controls Unitary Products... -
Page 32: Operation
30 seconds. Additionally, the indoor blower has a delay of The call is passed to the unit control board (UCB), which then 10 seconds between operations. determines whether the requested operation is available and, if so, which components to energize. Johnson Controls Unitary Products... -
Page 33: No Outdoor Air Options
(i.e. first stage has energized the economizer), "Y2" will ener- pressor is inactive, the condenser fans will be de-energized. gize compressor #1. If the outdoor air is above the set point, "Y2" will energize compressor #2. Johnson Controls Unitary Products... -
Page 34: Low-Pressure Limit Switch
(RA) will be energized. After completing the call for cooling is still present at the end of the ASCD and the specified fan on delay for heating, the UCB will the freezestat has closed, the unit will resume operation. Johnson Controls Unitary Products... -
Page 35: Electric Heating Operation Errors
10 seconds. The ICB then checks for the presence of flame. If flame is detected, the ICB enters a flame stabilization period. If flame was not detected, both main valves close, and a retry operation begins. Johnson Controls Unitary Products... -
Page 36: Second Stage Of Heating
IDM is de- This limit is monitored regardless of unit operation status, i.e. energized the IDM is re-energized. The second stage (MV2) this limit is monitored at all time. main valve is not monitored for closure after energization. Johnson Controls Unitary Products... -
Page 37: Safety Controls
P I P E ( B L U E O N L Y ) B U R N E R B R A C K E T I G N I T O R FIGURE 26 - TYPICAL FLAME Johnson Controls Unitary Products... -
Page 38: Start-Up (Cooling)
Make sure that the vent outlet and combustion air inlet are free of any debris or obstruction. Johnson Controls Unitary Products... -
Page 39: Shut Down
This unit has two stages of gas heat. The first stage is 60% of the full fire input and is considered the minimum input for the furnace. The intended input for each furnace is shown in the Johnson Controls Unitary Products... -
Page 40: Adjustment Of Temperature Rise
CSA rating plate and the data in Table 26. After the temperature rise has been determined, the CFM can be calculated as follows: FM = Btu Input x (1.08 x °F) FIGURE 27 - TYPICAL GAS VALVE Δ Johnson Controls Unitary Products... -
Page 41: Charging The Unit
Verify proper oper- connections with line terminals. ation after servicing. When not necessary, shut off all electric power to the unit prior to any of the following maintenance proce- dures so as to prevent personal injury. Johnson Controls Unitary Products... -
Page 42: Dw Flash Codes
11 Flashes Flashing Cooling 12 Flashes Unit Locked Out due to Fan Overload Switch Failure 13 Flashes Flashing Compressor Held Off due to Low Voltage 14 Flashes EEPROM Storage Failure No Power or Control Failure Non-alarm condition. Johnson Controls Unitary Products... -
Page 43: Unit Control Board Option Setup
Option Setup mode. parameters for the currently displayed mode When saving, the control board only saves the (Option Byte or Heat Delay). parameters for the currently displayed mode (Option Byte or Heat Delay). Johnson Controls Unitary Products... -
Page 44: Heat Delay
Energized With W1 Off Second Stage Gas Valve Gas Valve Energized With First Stage Non-std Non-std Gas Valve Off Gas Flow Gas Pressure Ignition Lockout Gas Valve Flame Sensor No Power Or Control STEADY OFF 24VAC or Control Failure Johnson Controls Unitary Products... - Page 45 ID Blower? ID Blower? for Cooling? FIGURE 30 - BASIC TROUBLESHOOTING FLOWCHART Power to Call for Voltage @ heat? Gas Valve? Unit Energize ID Initialize ASCD Blower Montior FIGURE 31 - POWER ON FLOW CHART Johnson Controls Unitary Products...
- Page 46 - p r e s s u r e s w i t c h d i f f e r e n t l y t h a n o t h e r i n p u t s . FIGURE 32 - TRIP FAILURE FLOW CHART Johnson Controls Unitary Products...
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Page 47: Cooling Troubleshooting Guide
On calls for cooling, the supply air blower motor is operating locked out, cancel any call for cooling. This will reset any but compressor #1 is not (the room thermostat fan switch is in compressor lock outs. the “AUTO” position). Johnson Controls Unitary Products... - Page 48 UCB. Disconnect the C1 terminal wire and jumper it to the Y1 terminal. DO NOT jump the Y1 to C1 termi- nals. If the compressor engages, the UCB has faulted. 16. If none of the above correct the error, replace the UCB. Johnson Controls Unitary Products...
- Page 49 If it is hot, the compres- UCB must be replaced. sor may be off on inherent protection. Cancel any calls for cooling and wait for the internal overload to reset. Test again when cool. Johnson Controls Unitary Products...
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Page 50: Gas Heat Troubleshooting Guide
M3 contactor, and check the room thermostat for contact between R and G that the contactor is pulled in. Check for loose wiring during “W1” calls. between the contactor and the supply air blower motor. Johnson Controls Unitary Products... - Page 51 If present, go to step 4. If 24 volts is not present, “BURNER/ORIFICE INSTRUCTIONS.” Clean or replace the either pressure or rollout switch is not closed. Or the burner orifices and burners as needed. draft motor is not sufficiently evacuating the heat Johnson Controls Unitary Products...
- Page 52 Subject to change without notice. Printed in U.S.A. 66389-BIM-C-1208 Copyright © 2009 by Johnson Controls, Inc. All rights reserved. Supersedes: 66389-BIM-B-0606 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...
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